Water Resistant Paper and Solution for Producing Same and Building Structure Employing Same

ABSTRACT

A waterproof architectural element comprising an elongated panel member composed of compressed fibrous material having a first planar surface and an opposed second planar surface. At least one elongated cellulose layer is composed of Kraft paper having paper basis weight between 30 and 90 pounds and an average thickness between 0.003 and 0.009 inches. The elongated substrate has a first planar face and an opposed second planar face. A polymeric layer overlies at least a portion of the first planar face of the elongated substrate and comprises a polymeric blend of between 50 and 80 wt. % styrene butadiene copolymer and 0.2 and 3 wt. % of a cellulose ether compound. The cellulose ether compound comprises hydrogen or an alkyl group selected from the group consisting of methyl, ethyl, hydroxyethyl, hydroxypropyl carboxymethyl, hydroxyethyl methyl, hydroxypropyl and between 30 and 50 wt. % calcium carbonate and water.

TECHNICAL FIELD

The present disclosure is directed to chemical compositions forimparting water resistance to cellulosic materials, and moreparticularly, the present disclosure is directed to solutions andmethods for imparting water resistance to paper sheet stock.

BACKGROUND

Structural components composed of compressed agricultural fiberstructural panels provide a sustainable and ecologically friendlybuilding component that are both sturdy and economical. Compressedagricultural fiber structural panels offer advantages of constructionspeed and efficiency together with lowering construction waste andLeadership Energy and Environmental Design (LEED) advantages. Compressedagricultural fiber panels have a negative carbon footprint, highinsulation values, and the ability to produce a tight building envelope.

Compressed agricultural fiber structural panels include a compactedfibrous core composed of a suitable cellulosic material such as variousprocessed vegetative material derived from agricultural fiber such asstraw, or the like. The compressed cellulosic material can be surroundedby a containment material such as in industrial packing paper such asKraft liner paper. The compressed or compacted cellulosic core can havea suitable density and dryness sufficient to provide the structuralstability and strength necessary to meet acceptable building and loadstandards.

In order to maintain the structural integrity of the compressed fiberstructural panels, it is necessary to avoid exposure to water after theinstallation process. Kraft paper is an ecologically friendly and lightweight option for the containment layer but can permit water incursion.Heretofore, the use of such architectural components has been limited touse in internal wall structures and the like. Use of such structures forexposed weather bearing walls has been extremely limited due to thedegradation caused by water incursion.

Thus, it would be desirable to provide a water-based, environmentallyfriendly chemical composition that can impart water resistance tofibrous materials such as Kraft paper and the like. It would also bedesirable to provide a polymeric material that can impart a durablewater-resistant coating to Kraft paper and the like. It is alsodesirable to provide an architectural structure composed of a compressedfibrous material surrounded by a containment material that provides theadvantages of Kraft paper while providing a containment surface that isintegral to the core element and provides enhanced water resistance.

SUMMARY

A coating composition that includes between 20 and 50 wt. % of a styrenebutadiene copolymer, between 20 and 40 wt. % of calcium carbonate havinga median particle size distribution between 10 μmm to 100μm, between 0.2and 1.0 wt. % of a cellulose ether compound, between 0.3 and 1.0 wt. %of an ammonia compound, between 0 and 1.0 wt. % of an anti-foamingagent, and water.

A composite structure that includes an elongated substrate having afirst planar face and a second planar face opposed to the first planarface. The elongated substrate is composed of Kraft paper having a paperbasis weight between 30 and 90 pounds, an average thickness between0.003 and 0.009 inches, and a polymeric layer overlying at least aportion of the first planar face of the elongated substrate. The coatingcomposition includes between 20 and 50 wt. % of a styrene butadienecopolymer, between 20 and 40 wt. % of calcium carbonate having a medianparticle size distribution between 10 μm to 100 μm, between 0.2 and 1.0wt. % of a cellulose ether compound, between 0.3 and 1.0 wt. % of anammonia compound, between 0 and 1.0 wt. % of an anti-foaming agent, andwater. The coating composition, when dried, is composed of between 50and 80 wt. % of a styrene butadiene copolymer, between 0.2 and 3 wt. %of a cellulose ether compound, between 30 and 50 wt. % of calciumcarbonate.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features, advantages and other uses of the present apparatuswill become more apparent by referring to the following detaileddescription and drawing in which:

FIG. 1 is a cross-section of a representative compressed fiber boardstructural component having an embodiment of the composition asdisclosed herein and applied thereon;

FIG. 2 is a cross-section of the polymeric composition as disclosedherein and applied thereon; and

FIG. 3 is a process diagram of the preparation of the structuralcomponent as disclosed herein.

DETAILED DESCRIPTION

The present disclosure is predicated on the unexpected discovery thatthe novel polymeric formulation as disclosed herein can form a durablecoating that is resistant to exposure to environmental challenges suchas water. It is also predicated on the discovery that the polymericformulation as disclosed herein can form a bonded coating overlying acellulose-containing substrate that is both durable and resistant toenvironmental challenges. It has also been discovered that the polymericcomposition as disclosed herein when applied to a containment layeroverlying a compressed structural fiberboard composed of agriculturallyderived fiber material can integrally bond with the containment layer ina manner that strengthens the containment layer and impartsenvironmentally imperviousness to the associated structural member.

Disclosed herein is a polymeric that can be applied on a suitablecellulose-containing substrate as a liquid material and harden afterapplication to a polymeric layer that adheres and/or integrates with theassociated substrate. The coating composition that is employed includesa styrene butadiene copolymer dispersed in an aqueous carrier, togetherwith calcium carbonate having a median particle size distributionsufficient to disperse into the aqueous carrier and a cellulose ethercomponent. The coating composition also includes an ammonia compound andan optional anti-foaming agent.

Application onto the suitable cellulose-containing substrate can beaccomplished by any suitable manner as by roller application, brushing,or the like. The applied polymeric composition can be applied as aliquid that adheres to the cellulose-containing substrate and hardensinto a polymeric coating upon evaporation of the aqueous carrier.Without being bound to any theory, it is believed that the resultingpolymeric composition includes binding sites that interact withcellulose-containing material in the substrate to form chemical bondsbetween the cellulose-containing material and functional groups presenton the resulting polymeric coating. It is also theorized that theapplied material penetrates into regions of the cellulose-containingsubstrate, particularly those proximate to the first planar face of thecellulose-containing substrate and polymerizes therearound.

In certain embodiments, the coating composition includes a styrenebutadiene copolymer that is present in an amount between 20 and 50 wt.%. The styrene butadiene copolymer employed can have the generalformula:

in which n is an integer between 50 and 15,000. In certain embodiments,the styrene butadiene copolymer can have a random copolymer. It iscontemplated that the styrene butadiene copolymer that is employed canhave a number average molecular weight between 50,000 and 500,000 incertain embodiments. Where desired or required, the styrene butadienecopolymer in the coating composition as applied can be present in anaqueous carrier in either a dispersed or emulsified state, or mixture ofthe two. One non-limiting example of a styrene butadiene copolymericmaterial suitable for use in the composition as disclosed herein iscommercially available from Omnova Solutions Incorporated under thetrade name PLIOTEC® WPM120. It is believed that PLIOTEC® WPM120 is amilky white liquid proprietary composition having a Brookfield viscositybetween 50-400 cps (LVT #2 spindle, 60 rpm@ 25° C.). The liquid has a pHbetween 8 and 9 and has a solids content between 51% and 53% composed inwhole or in part of a styrene butadiene copolymer having a specificgravity of 1.02 and a glass transition temperature (Tg) midpoint of 5°C. PLIOTEC® WPM120 material is free of alkylphenol ethoxylate componentsand is believed to be a styrene butadiene emulsion.

In certain embodiments, the styrene butadiene copolymer can be presentin the application composition in a concentration between 20 and 40 wt.%.

When the styrene butadiene copolymeric component is introduced into theapplication solution as PLIOTEC® WPM120, it is contemplated that thePLIOTEC® liquid material can constitute between 40 and 50 wt. % of theapplication solution in certain embodiments, while in some embodiments,the PLIOTEC® WPM120 component can be present in the application solutionin an amount between 41 and 46 wt. %.

The application solution can also include a cellulose compound dispersedin the liquid in a concentration between 0.003 and 1.0 wt. %. It iscontemplated that in certain embodiments, the cellulose can be presentin an amount between 0.3 to 1. 0 wt. %, while in some embodiments, thecellulose ether can be present in an amount between 0.3 and 0.75 wt. %.

The cellulose ether can have the general formula:

wherein each R is hydrogen or an alkyl group selected from the groupconsisting of methyl, ethyl, hydroxyethyl, hydroxypropyl carboxymethyl,hydroxyethyl methyl, hydroxypropyl, and mixtures thereof; wherein n isinteger between 50 and 1000.

In certain embodiments, it is contemplated that each R will be hydrogenor an alkyl group selected from the group consisting of methyl, ethyl,hydroxyethyl and mixtures thereof. Non-limiting examples of commerciallyavailable cellulose ethers include METHOCEL commercially available fromDow Chemical Company. Suitable cellulose ethers compounds will be thosewhich can impart a viscosity between 400 cps and 2000 cps when added toan aqueous medium. Non-limiting examples of suitable commerciallyavailable cellulose ethers include METHOCEL 228. Without being bound toany theory, it is believed that the cellulose ether component serves toprevent water separation during polymerization and to maintain thevarious solid components in solution.

The coating composition, as disclosed herein, also includes a calciumcarbonate component. The calcium carbonate component employed will havea median particle size between 1 μmm to 1000 μm. In certain embodiments,it is contemplated that the calcium carbonate component will have anaverage particle size between 100 μmm and 300 μmm. Where desired orrequired, the calcium carbonate can be a combination of various gradesof calcium carbonate and can have a mesh size between 80 μmm and 60 μmm.

The calcium carbonate component can be present in an amount between 20and 40 wt. %. In certain embodiments, the calcium carbonate componentcan be present in an amount between 25 and 35 wt. %. Without being boundto any theory, it is believed that the fine particulate calciumcarbonate is integrated into the polymerizing material as the aqueouscomponent evaporates, and the styrene butadiene copolymer presentlydispersed in the aqueous carrier polymerizes in contact with thecellulose substrate.

The aqueous application composition as disclosed herein also includes anammonia compound present in an amount between 0.3 and 1.0 wt. %. Incertain embodiments, the ammonia compound is present in an amountbetween 0.3 and 0.7 wt. %. The ammonia compound can be selected from thegroup consisting of ammonia, ammonium persulfate, ethylenediamine, andmixtures thereof. In certain embodiments, it is contemplated that theammonia compound will be ammonia. Without being bound to any theory, itis contemplated that the ammonia compound modulates the polymerizationreaction that occurs with removal of the aqueous component afterapplication.

The application composition can also include between 0 and 1.0 wt. % ofat least one anti-foaming agent. The anti-foaming agent can be onesuitable for inhibiting solution foaming in the composition as thematerial is applied to the cellulose-containing substrate. It is alsocontemplated that the anti-foaming agent can inhibit foaming duringformulation. Where desired or required, the anti-foaming agent can be acompound selected from the group consisting of fatty alcohols, fattyacid soaps, fatty acid ethers, silicone-based defoamers and mixturesthereof. Non-limiting examples of suitable antifoaming agents includepolyoxyethylene octyl phenol ether (Polyoxyethylene Octylphenol Ether)and the heavy paraffin refined oil hydrotreated (Hydrotreated heavyparaffinic distillate) 10˜20: The mixture was mixed in a weight ratio of80 to 90 preferably used and may include 0.1 to 3% by weight.

Also disclosed herein is a composite structure 10 as shown in FIGS. 1and 2. The composite structure 10 includes an elongated substrate 14.The elongated substrate 14 can have any suitable length and width aswell as thickness. In certain embodiments, the thickness of the layer ofthe elongated substrate 14 will be between 0.003 inches and 0.050inches. In certain embodiments, the thickness of the elongated substrate14 can be between 0.003 and 0.009 inches.

It is contemplated that the elongated substrate 14 will be composed of amaterial that is both light weight and durable. In certain embodiments,the elongated substrate layer 14 can be composed in whole or in part ofa suitable cellulosic material such as Kraft paper. The Kraft paperemployed in the elongated substrate 14 can have a paper basis weightbetween 10 and 100 pounds in some embodiments, while the paper basisweight can be between 30 and 90 pounds in some embodiments.

The elongated substrate 14 can have a first planar face 24 and a secondplanar face 22. The second planar face 22 is opposed to and generallyoriented substantially parallel to the first planar face 24. In theembodiment depicted in FIGS. 1 and 2, the first planar face 24 isconfigured to be oriented in an outwardly facing direction relative toan associated structural or elongated panel member 12. The opposedsecond planar face 22 is configured to be oriented inwardly and can beconfigured with a suitable adhesive or the like to facilitate attachmentand/or bonding to the associated structural member 12 such as a boardmade of compressed agricultural fibers.

The composite structure 10 also has a polymeric layer 16 that overliesat least a portion of the first planar face 24 of the elongatedsubstrate 14. The polymeric layer 16 has a first planar face 28 that isoutwardly facing and is sufficiently durable to withstand exteriorenvironmental challenges such as rain water and the like. The polymericlayer 16 also has an opposed planar region 26 that is affixed to theoutwardly oriented first face 24 of the substrate layer 14 in agenerally integral manner.

The polymeric layer 16 can have a thickness suitable to prevent waterincursion or migration through to the substrate 14. In certainembodiments, the polymeric layer 16 will have a thickness between 0.001inches and 0.005 inches. It is also contemplated that a portion of thepolymeric material applied to the elongated substrate 14 can penetrateinto the outer region of the cellulosic material of the elongatedsubstrate 14 forming a composite composed of polymeric material andsubstrate (not shown).

The polymeric layer 16 can be composed of a solidified polymericmaterial that comprises the following: between 50 and 80 wt. % of astyrene butadiene copolymer; between 0.2 and 3 wt. % of a celluloseether; and between 30 and 50 wt. % calcium carbonate. In certainembodiments, the styrene butadiene copolymer is polymerized in a blendedrelationship with the calcium carbonate component and the celluloseether component, the cellulose ether component having the generalformula:

wherein each R is hydrogen or an alkyl group selected from the groupconsisting of methyl, ethyl, hydroxyethyl, hydroxypropyl carboxymethyl,hydroxyethyl methyl, hydroxypropyl; and wherein n is integer between 50and 1000.

The elongated panel member 12 has a first outwardly oriented face 20 andan opposed second inwardly oriented face 18. The substrate layer 14 canbe affixed to the first outwardly oriented face 20 of the elongatedpanel member 12 by any suitable means. In many embodiments, it isdesirable to affix the substrate layer 14 in a manner that does notcompromise the structural integrity of the substrate layer 14. Incertain embodiments, a heat-activated polymeric adhesive layer isinterposed between the second inwardly oriented face 18 of the substratelayer 14 and the first outwardly oriented face 20 of the elongated panelmember 12.

The elongated panel member 12 is composed of compressed agriculturalfibers. Non-limiting examples of such materials are those found in U.S.Pat. Nos. 5,945,132; 6,143,220; and 8,052,842, the specification ofwhich is incorporated by reference herein. Where desired or required,the elongated panel member 12 can include suitable fittings, joists, andother edge elements to facilitate assembly into the finished structure.The substrate layer 14 can overly the various fitting and end joists ina manner that contains the compressed fiber material of the elongatedpanel member 12 with the polymeric layer 16 overlying both.

The outwardly oriented face 28 of the polymeric layer 16 may be paintedand have other decorative coatings adhered thereto. Without being boundto any theory, it is believed that the calcium carbonate componentintegrates into the styrene-butadiene copolymer after the material hasbeen applied to the substrate layer or material 14. It is also theorizedthat the calcium carbonate component integrated in the polymeric matrixprovides binding sites that strengthen the resulting polymer and canenhance adhesion of later applied coating compositions such as paintsand the like.

Where a roughened or more stucco-like surface is desired, it iscontemplated that texturing materials can be incorporated into thepolymeric matrix prior to application of the composition on the firstouter face 24 of the substrate layer or material 14. It is alsoconsidered with the purview of the present disclosure to incorporatevarious aesthetic enhancements where desired or required. Non-limitingexamples of suitable texturing materials include Portland cementcomponents, silica sand, micronized plastic beads, and other geometricshapes and the like. Non-limiting examples of suitable aestheticmaterials can include various pigmented flakes and the like. Whereemployed, it is contemplated that the texturing material can be presentin an amount between 0 and 15 wt. %, with certain embodiments havingamounts between 2 and 7 wt. %. Where pigmenting agents are employed itis contemplated that they can be present in an amount between 0 and 5wt. %.

Where desired, the polymeric layer 16 can be composed of an innersublayer proximate to the substrate layer 14 that is composed of theaforementioned composition. Overlying the inner sublayer can be at leastone outer layer that incorporates one or more of the texturizing and/oraesthetic enhancing components.

Without being bound to any theory, it is also believed that theconstruct as disclosed herein exhibits and imparts impact and waterresistance both during construction and when employed in builtstructures.

The composition as disclosed herein can be formulated according to thefollowing process 100, as shown in FIG. 3. An admixture of a celluloseester compound and water, as shown in step 110, can be formed byintegrating cellulose ester having the general formula:

wherein each R is hydrogen or an alkyl group selected from the groupconsisting of methyl, ethyl, hydroxyethyl, hydroxypropyl carboxymethyl,hydroxyethyl methyl, hydroxypropyl, and wherein n is integer between 50and 1000. The cellulose ester compound can be added in an amountsufficient to provide a composition viscosity between 2000 and 6000 cps,with composition viscosity ranges between 2000 and 4000 cps beingemployed in certain embodiments. Addition and integration can beaccomplished by medium to low shear mixing between 100 and 400 rpm, with100 to 250 rpm being employed in certain embodiments. The amount ofcellulose ester compound admixed into the water can be sufficient toprovide a liquid application composition having between 0.003 and 1.0wt. % of cellulose ether compound in certain embodiments.

Once the material is admixed, a sufficient quantity of an aqueousemulsion composed of between 40 and 50 wt. % of an anionic styrenebutadiene copolymer having a specific gravity between 1.0 and 1.10 isadded to the resulting composition in an amount sufficient to reduce thecomposition viscosity to a level between 1000 and 1500 cps, as shown instep 120. One non-limiting example of a suitable styrene butadieneemulsion is PLIOTEC® WPM 120. The styrene butadiene emulsion can beadded with mixing under medium to low shear at a speed between 100 and400 rpm in certain embodiments. In certain embodiments, it iscontemplated that the quantity of styrene butadiene copolymer added tothe reaction mixture will be that sufficient to provide a styrenebutadiene copolymer in an amount between 20 and 50 wt. % of theresulting coating composition as applied.

After the styrene butadiene copolymer is thoroughly integrated, anammonia compound can be added to the admixture in an amount between 0.3and 1.0 wt. %, as shown in step 130. The ammonia compound can beselected from the group consisting of ammonia, ammonium persulfate,ethylenediamine, and mixtures thereof.

Calcium carbonate can be added simultaneously or subsequent to theaddition of the ammonia compound. The calcium carbonate can beparticulate material having a median particle size between 1 μm to 1000μmm in certain embodiments and between 100 μmm and 300 μmm in someembodiments. It is contemplated that the amount of calcium carbonateadded can be between 20 and 40 wt. %.

The composition can also include suitable defoamers in an amount between0 and 0.5 wt. % which can be added as desired during the productformulation.

The resulting composition is stable and can be stored for up to 12months. The resulting composition can be applied to a suitable Kraftpaper substrate by rolling, spraying, brushing etc., as shown in step140, and hardens to a solid uniform water resistant coating. The craftpaper substrate can be affixed in an overlying relationship to at leastone surface of a suitable board construct composed of compressedagricultural fibers as described above.

The following example is provided to further illustrate the presentdisclosure. It is provided for illustrative purposes and is not to beconstrued as a limitation of the claims or the disclosure in general.

EXAMPLE I

In order to assess the performance of the coating composition andcomponents prepared including at least one layer of the composition asdisclosed herein, the following example has been provided.

A coating composition is prepared by admixing sufficient cellulosecompound under the trade name METHOCEL 228 commercially available fromDow Chemical in water with low to medium shear mixing at a speed of 100rpm to provide a cellulose compound concentration of 0.5 wt. % and acomposition viscosity of approximately 3000 cps. It is believed that theMETHOCEL 228 material is an aqueous material composed of cellulose etherand having an initial composition viscosity between 2000 and 6000 cps.

Once the material is admixed, a volume of PLIOTEC® WPM 120 anionicstyrene butadiene emulsion is added to the solution with mixing undermedium to low sheer at a speed of 200 rpm. The amount added issufficient to reduce the solution viscosity to 1000 cps and providestyrene copolymer in the end composition of 40 wt. %. After the styrenebutadiene copolymer is thoroughly integrated, ammonia is added to theadmixture at 0.3 wt. % based on the compositional weight with thesimultaneous addition of particulate calcium carbonate having a medianparticle size of 200 μmm to provide a composition containing 30 wt. % ofcalcium carbonate.

The resulting composition is stable and can be stored for up to 12months.

EXAMPLE II

The composition outlined in Example I is applied to a 12 inches×12inches Kraft paper substrate having a having paper basis weight of 40lbs and an average thickness of 0.006 inches by roller application. Thecomposition is applied to a thickness of 0.002 inches and allowed to dryfor an interval of three hours and is physically inspected. The appliedcoating has a generally smooth surface that is dry to the touch andprovides generally uniform adhesion to the underlying Kraft paper.

EXAMPLE III

A second layer of the composition outlined in Example I is applied inoverlying relationship to the first applied coating layer to thecontrast prepared in Example II by roller application to a thickness of0.002 inches to produce a total coating layer of 0.004 inches. Theapplied coating layer is allowed to dry for an interval of three hoursand is physically inspected. The applied coating layer has a generallysmooth surface that is dry to the touch and adheres to the underlyinglayer.

EXAMPLE IV

The composition outlined in Example I is applied to a 5 feet×5 feetpanel of compressed wheat straw that is obtained from AgriboardIndustries of Vernon, Tex. The compressed wheat straw panel is preparedby adhesively applying a piece of Kraft paper to one five-foot surfaceof the compressed wheat straw panel. The Kraft paper material appliedhas paper basis weight of 40 lbs. and an average thickness of 0.006inches. The composition is applied to a thickness of 0.002 inches andallowed to dry for an interval of three hours and is physicallyinspected. The applied coating layer has a generally smooth surface thatis dry to the touch.

The resulting construct is further inspected. The underlying compressedwheat straw panel, the Kraft paper, and the applied coating layer forman integral unit that can be employed in further constructionactivities.

EXAMPLE V

For purposes of analysis, the construct prepared in Example IV iscompared with a wheat straw panel of similar dimensions and a wheatstraw panel having Kraft paper adhesively attached. It is found that theKraft paper-to-panel bond strength and delamination resistance isincreased in constructs having the layer of the coating composition ofExample I and those described elsewhere in this disclosure.

The three test pieces are tested for impact resistance by dropping a50-gram round pellet from vertical heights of 5 feet and 10 feet,respectively, onto a planar surface of the respective panels positionedvertical to the test piece dropped. Impact dimpling is detected in thenon-covered compressed wheat straw panel and in the Kraft paper-coveredpanel but not in the construct as outlined having the coatingcomposition defined in Example I. This construct is visually examinedafter impact testing, and no appreciable cracking is observed at or nearthe impact site.

To test water repellency, test pieces according to the threeconstructions outlined are each positioned horizontally,perpendicularly, and at a 45°, and 25 ml portions of water are pouredonto the planar surface. The water is slowly absorbed in the uncoveredpanel member and into the Kraft paper in the uncovered Kraft paperconstruct. The water appears to pool on the surface of the coatedconstruct. The water samples cause similar effects at perpendicular andangular orientations as noted above. It is concluded that the coatingcomposition imparts water resistance to the coated construct.

While the present disclosure has been described in connection with whatis presently considered to be the most practical and preferredembodiment, it is to be understood that the present disclosure is not tobe limited to the disclosed embodiments but, on the contrary, isintended to cover various modifications and equivalent arrangementsincluded within the spirit and scope of the appended claims, which scopeis to be accorded the broadest interpretation so as to encompass allsuch modifications and equivalent structures as is permitted under thelaw.

What is claimed is:
 1. A coating composition comprising: between 20 and50 wt. % of an anionic styrene butadiene copolymer; between 20 and 40wt. % of calcium carbonate, the calcium carbonate having a medianparticle size between 1 μm to 1000 μmm; between 0.003 and 1.0 wt. % of acellulose ether compound, the cellulose ether compound having thegeneral formula:

wherein each R is hydrogen or an alkyl group selected from the groupconsisting of methyl, ethyl, hydroxyethyl, hydroxypropyl carboxymethyl,hydroxyethyl methyl, hydroxypropyl, and wherein n is integer between 50and 1000; between 0.3 and 1.0 wt. % of an ammonia compound, the ammoniacompound selected from the group consisting of ammonia, ammoniumpersulfate, ethylenediamine, and mixtures thereof; between 0 and 1.0 wt.% of an anti-foaming agent selected from the group consisting of fattyalcohols, fatty acid soaps, fatty acid ethers, silicone-based defoamers,and mixtures thereof; and water.
 2. The composition of claim 1 whereinthe styrene butadiene copolymer is present in a concentration between 20and 40 wt. % and has a general formula:

wherein n is an integer between 50 and 500,000.
 3. The composition ofclaim 2 wherein the cellulose ester compound is selected from the groupconsisting of methyl cellulose, hydroxyethyl cellulose, hydroxyethylmethyl and mixtures thereof and is present in an amount between 0.003and 0.75 wt. %.
 4. The composition of claim 1 wherein the anti-foamingagent is present in an amount between 0.1 and 0.6 wt. % and is asiloxane.
 5. The composition of claim 1 wherein the ammonia compound ispresent in an amount between 0.2 and 0.5 wt. %.
 6. The composition ofclaim 1 wherein the calcium carbonate is present between 25 and 35 wt. %and has a median particle size between 100 μm to 300 μm.
 7. Thecomposition of claim 1 further comprising a least one texturing agent.8. A composite structure comprising: an elongated substrate, theelongated substrate composed of Kraft paper having paper basis weightbetween 30 and 90 pounds and an average thickness between 0.003 and0.009 inches, the elongated substrate having a first planar face and asecond planar face, the second planar face opposed to the first planarface; a polymeric layer overlying at least a portion of the first planarface of the elongated substrate, the polymeric layer comprising apolymeric blend of: between 50 and 80 wt. % of a styrene butadienecopolymer: between 0.2 and 3 wt. % of a cellulose ether compound, thecellulose ether compound having the general formula:

wherein each R is hydrogen or an alkyl group selected from the groupconsisting of methyl, ethyl, hydroxyethyl, hydroxypropyl carboxymethyl,hydroxyethyl methyl, hydroxypropyl, and wherein n is integer between 50and 1000; and between 30 and 50 wt. % of calcium carbonate.
 9. Thecomposite structure of claim 8 further comprising: an elongated panelmember having a first face and an opposed second face, the elongatedbody composed of compressed fibrous material, wherein the second face ofthe elongated substrate is in overlying relationship with at least thefirst face of the elongated panel member.
 10. The composite structure ofclaim 8 further comprising at least one adhesive layer interposedbetween the second face of the elongated substrate and the first face ofthe elongated body structure.
 11. A waterproof architectural elementcomprising: an elongated panel member, the elongated panel membercomposed of compressed fibrous material, the elongated panel memberhaving a first planar surface and an opposed second planar surface; atleast one elongated substrate, the elongated substrate composed of anelongated cellulose layer composed of Kraft paper having paper basisweight between 30 and 90 pounds and an average thickness between 0.003and 0.009 inches, the elongated substrate having a first planar face anda second planar face, the second planar face opposed to the first planarface, wherein the second planar face of the elongated substrate is inoverlying relationship to at least a portion of at least one of thefirst planar surface of the elongated panel member, the second planarsurface of the elongated panel member, or both; a polymeric layeroverlying at least a portion of the first planar face of the elongatedsubstrate, the polymeric layer comprising a polymeric blend of: between50 and 80 wt. % of a styrene butadiene copolymer: between 0.2 and 3 wt.% of a cellulose ether compound, the cellulose ether compound having thegeneral formula:

wherein each R is hydrogen or an alkyl group selected from the groupconsisting of methyl, ethyl, hydroxyethyl, hydroxypropyl carboxymethyl,hydroxyethyl methyl, hydroxypropyl, and wherein n is integer between 50and 1000; between 30 and 50 wt. % of calcium carbonate; and water. 12.The waterproof architectural element of claim 11 further comprising atleast one adhesive layer interposed between the second face of theelongated substrate and the first face of the elongated body structure.13. The waterproof architectural element of claim 10 wherein thepolymeric layer further comprises an outermost layer, the outermostlayer comprising a polymeric blend of: between 50 and 80 wt. % of astyrene butadiene copolymer: between 0.2 and 3 wt. % of a celluloseether compound, the cellulose ether compound having the general formula:

wherein each R is hydrogen or an alkyl group selected from the groupconsisting of methyl, ethyl, hydroxyethyl, hydroxypropyl carboxymethyl,hydroxyethyl methyl, hydroxypropyl, and wherein n is integer between 50and 1000; between 30 and 50 wt. % of calcium carbonate; and at least onetexturing agent.
 14. A high-performance polymer coating compositionformed by the steps of: admixing a composition of cellulose compound andwater to form a composition of having a viscosity between 2000 and 6000cps, wherein the cellulose ether has the general formula:

wherein each R is hydrogen or an alkyl group selected from the groupconsisting of methyl, ethyl, hydroxyethyl, hydroxyethyl, hydroxypropylcarboxymethyl, hydroxyethyl methyl, hydroxypropyl, and wherein n isinteger between 50 and 1000; to the admixed composition of celluloseethers and water, adding an emulsion of water and an anionic styrenebutadiene copolymer in sufficient quantity to produce a solutionviscosity between 1000 to 1500 cps, wherein the emulsion of water andanionic styrene butadiene copolymer has a solids content between 40 and50 wt. % and a specific gravity between 1.00 and 1.10; adding an ammoniacompound to the resulting composition in an amount between 0.3 and 1.0wt. %; adding calcium carbonate to the admixed composition in an amountsufficient to provide calcium carbonate in the application compositionin an amount between 20 and 40 wt. %, the calcium carbonate the calciumcarbonate having a median particle size between 1 μm to 1000 μmm; andafter introducing the ammonia compound to the resulting composition,applying the liquid composition to a flexible paper substrate andallowing water in the applied material to evaporate.
 15. The method ofclaim 13 wherein the cellulose ester compound is added in an amountsufficient to provide an application composition containing between0.003 and 1.0 wt. % of the cellulose ether compound.
 16. The method ofclaim 14 wherein the cellulose ester compound is selected from the groupconsisting of methyl cellulose, hydroxyethyl cellulose, hydroxyethylmethyl and mixtures thereof.
 17. The method of claim 15 wherein thecellulose ester compound is present in amount between 0.03 d 0.75 wt. %.18. The method of claim 14 wherein the anionic styrene butadienecopolymer emulsion contains a styrene butadiene copolymer having thegeneral formula:

wherein n is an integer between 50 and 500,000.
 20. The method of claim17 wherein the amount of styrene butadiene emulsion added is sufficientto provide between 20 and 50 wt. % of a styrene butadiene copolymer inthe high performance coating composition.
 21. The method of claim 13wherein the calcium carbonate has an average particle size between 100μm and 300 μm.